OISD-STD-150

First Revision
.For restricted
Circulation only

Design and Safety Requirements

for
Liquefied Petroleum Gas Mounded Storage Facility

Prepared by

FUNCTIONAL COMMITTEE

OIL INDUSTRY SAFETY DIRECTORATE

7th Floor, New Delhi House
27-Barakhamba Road
New Delhi 110001
 NOTE

OISD publications are prepared for use in the oil and gas industry
under the Ministry of Petroleum and Natural Gas. These are the
property of Ministry of Petroleum and Natural Gas and shall not be
reproduced or copied and loaned or exhibited to others without
written consent from OISD.

Though every effort has been made to assure the accuracy and
reliability of data contained in these documents, OISD hereby
expressly disclaims any liability or responsibility for loss or damage
resulting from their use.

These documents are intended only to supplement and not to

replace the prevailing statutory requirements.
 FOREWORD

The Oil Industry in India is 100 years old. Because of various

collaboration agreements, a variety of international codes, standards
and practices have been in vogue. Standardisation in design
philosophies and operating and maintenance practices at a national
level was hardly in existence. This, coupled with feed back from
some serious accidents that occurred in the recent past in India and
abroad, emphasised the need for the industry to review the existing
state of art in designing, operating and maintaining oil and gas
installations.

With this in view, the Ministry of Petroleum and Natural Gas in 1986
constituted a Safety Council assisted by the Oil Industry Safety
Directorate (OISD) staffed from within the industry in formulating and
implementing a series of self regulatory measures aimed at
removing obsolescence, standardising and upgrading the existing
standards to ensure safe operations. Accordingly, OISD constituted
a number of functional committees of experts nominated from the
industry to draw up standards and guidelines on various subjects.

The first edition of the document on "Design and Safety

Requirements for Liquefied Petroleum Gas Mounded Storage
Facility” was published in august 2000. The present document is the
revised by functional committee based on the accumulated
knowledge and experience of industry members and the various
national, international codes and practices.

This document is meant to be used as supplement and not as a

replacement for existing codes and practices. Suggestions are
invited from the industry to improve the document further, and the
same may be addressed to

The Coordinator,
FUNCTIONAL COMMITTEE on
“Liquefied Petroleum Gas Mounded Storage Facility”

Oil Industry Safety Directorate,

7th Floor, New Delhi House
27-Barakhamba Road
New Delhi 110001
 FUNCTIONAL COMMITTEE
(First Edition - August, 2000)

NAME ORGANISATION

LEADER
Shri Mrinal Roy Indian Oil Corpn. Ltd

MEMBERS
Shri Manmohan Singh Bharat Petroleum Corpn. Ltd.
Shri M.M. Mandal Gas Authority of India Limited..
Shri K.S. Rao Hindustan Petroleum Corpn. Ltd
Shri K.G. Malhotra Engineers India Limited

SPECIAL INVITEE
Shri R.H. Bhalekar Department of Explosives
Dr. M.B. Mishra Project Development (India) Ltd.

CO-ORDINATOR
Shri A.Mishra Oil Industry Safety Directorate

FUNCTIONAL COMMITTEE
(First Revision )

LEADER
Shri A. Mishra IBP Co. Ltd.

MEMBERS
Shri Ajai Nigam Department of Explosives
Shri N. Dasgupta Bharat Petroleum Corpn. Ltd.
Shri A. Dutta Bharat Petroleum Corpn. Ltd
Shri Samuel Babu Kochi Refineries Ltd.
Shri A.K. Gupta Indian Oil Corpn. Ltd.
Shri S. Mustyalwar Hindustan Petroleum Corpn. Ltd.
Shri P.N. Dubey Indian Oil Corpn. Ltd., Barauni
Refinery

MEMBER COORDINATOR
Shri S.C. Gupta Oil Industry Safety Directorate

In addition to the above, several experts from the industry contributed in the preparation, review
and finalisation of this document.
 CONTENTS

________________________________________________________________

Sr. No. DESCRIPTION Page No.

________________________________________________________________

1.0 INTRODUCTION 1

2.0 SCOPE 1

3.0 DEFINITIONS 1

4.0 LOCATION AND SAFETY DISTANCES 4

5.0 MOUNDED LPG STORAGE FACILITIES 5

6.0 FITTINGS AND INSTRUMENTATION ON A VESSEL 8

7.0 ELECTRICAL AREA CLASSIFICATION 9

8.0 FIRE DETECTION / PROTECTION SYSTEM 9

9.0 OPERATION, MAINTENANCE AND INSPECTION 10

10.0 REFERENCES 11
________________________________________________________________

ANNEXURE

I. General Guidelines for Cathodic Protection System

DRAWINGS

I. Typical Mounded Storage Vessel

II. Typical Mounded Storage Construction Methodology
III. Bottom Outlet with Inspection Tunnel
IV. Typical Nozzle arrangement mounted on Top of Dome with Sprinklers
System
V. Mounted Top Surface Construction
1.0 INTRODUCTION manhole covers, inspection covers fitted on
vessel(s).

Liquefied Petroleum Gas (LPG) handling Bullet

has many challenges due to its inherent
dangerous properties. Some of the major A horizontal pressure vessel used for
fires/explosions have underlined the need storage or transportation by rail/ road.
for total in depth review of design,
procedures maintenance fire fighting and Compressed Gas
safety aspects in LPG handling. The
conventional method of storage of LPG in Any permanent gas, liquefiable gas or gas
India is in a pressurised vessel installed dissolved in liquid under pressure or gas
aboveground. mixture which in a closed container
exercises a pressure either exceeding two
The mounded storage of LPG has proved to atmosphere (gauge) at the maximum
be safer compared to above ground storage working temperature, which for vessels
vessels since it provides intrinsically passive without insulation or refrigeration shall
and safe environment and eliminates the be considered as 55°C.
possibility of Boiling Liquid Expanding .
Vapour Explosion (BLEVE). The cover of the Explosive mixture
mound protects the vessel from fire
engulfment, radiation from a fire in close It is a mixture of combustion agent (oxidising
proximity and acts of sabotage or vandalism. substance-gaseous, liquid or solid) and a
The area of land required to locate a fuel (oxidisable substance- gaseous, liquid
mounded system is minimal compared to or solid) in such proportions that it could give
conventional storage. rise to a very rapid and violent oxidation
reaction liberating more energy than is
2.0 SCOPE dissipated through conduction and
convection causing practical effect of
This standard lays down minimum explosion.
requirements on safety, design, layout,
installation, operation, maintenance and Hazard Area Classification
testing of aboveground fully mounded bulk
vessels used for storage of Liquefied It is the classification of hazardous area
Petroleum Gas (LPG) installed in the zone wise/group wise, based on the nature
refineries, gas processing plants, terminals, of the flammable substance and the extent
bottling plants and auto LPG dispensing of presence of the explosive vapour- air
stations otherwise falling under the scope of mixture likely to be present under operating
any of the OISD standards namely OISD- conditions for the purpose of selection of the
STD-144, OISD-STD-116, OISD-STD-118, type of electrical equipment in the respective
OISD-GDN-169 and OISD-STD-210 as zone/area.
applicable. This standard only supplement to
the requirements of above mentioned OISD Bulk Vessels
standards as regards to mounded storage
facility for LPG. A pressure vessel of more than 1000 liters
water capacity used for storage or
transportation of compressed gas.

3.0 DEFINITIONS Water Capacity

Mounded Vessel (s) The volume of water in liters that the

container can hold at 15 oC.
A storage vessel(s) sited above ground and
completely covered by a mound of earth or
similar inert material except for nozzles,
Earthing & Bonding
Kerb Wall
Earthing is the provision of a safe path of
electrical current to ground, in order to A wall of appropriate height and size
protect structures, plant and equipment from constructed of suitable material and
the effects of stray electrical current, and designed to contain the LPG spillage and to
electrostatic discharge. direct it to a safe location around the storage
vessel.
Bonding is the provision of connecting
different parts of an equipment or system by
way of bond wire/strip so as to maintain Liquefied Petroleum Gas (LPG)
electrical continuity among all parts of the
system A mixture of certain light hydrocarbons
derived from petroleum, which are gaseous
Fire safe at normal ambient temperature and
atmospheric pressure but may be
As applied to valves, it is a provision of dual condensed to liquid state at normal ambient
seating to control leakage to acceptable temperature by the application of moderate
level even after damage due to fire. pressure, and which conforms to IS : 4576
or IS : 14861 (Auto LPG).
Fire proof/proofing
Purging
It is a passive means of protection of a
structure/equipment/vessel from exposure to It is the act of replacing the atmosphere
direct fire or flame impingement or within a equipment by an inert gas / LPG
prolonged exposure to high intensity radiant vapour in such a manner as to prevent the
heat flux, by the application of a coating of a formation of explosive mixture.
specified rating.
Reid Vapor Pressure
Flammability Range/Limits
Reid Vapor Pressure is the vapor pressure
It is the range in percentage by volume of in pounds per square inch (psi) at 100 Deg.
any flammable vapour which in admixture F as determined by Reid apparatus.
with air, forms an explosive mixture.
Statutory Authority
Flammable (or Inflammable)
It is an authority appointed under specific
Any substance which when tested in a Act or regulation for administering specific
specified manner will ignite when mixed with function under the Act/regulation.
air on contact with a flame and will support
combustion. “Chief Controller of Explosives”, hereafter
referred as CCOE, is the Statutory Authority
Gas-Free for administering the SMPV (U) Rules 1981.

It is a condition when the concentration of a “Chief Inspector of Factories" in a State/UT

flammable gas in equipment is well below is .the Statutory Authority for enforcement
the threshold limits (LEL) so that it is safe for of the Factories Act, 1948 and the
a man to enter into the equipment or to carry Factories Rules made thereunder.“
hot work there, as the case may be.
Sources of Ignition.
Hot Work
Devices or equipment which, because of
It is an activity, which may produce enough their mode, use or operation, are capable of
heat to ignite a flammable air-hydrocarbon providing required thermal energy to ignite
mixture or a flammable substance. flammable LPG-Air mixtures" when
introduced to such a mixture or when such a
mixture comes into contact with them.

SMPV (Unfired) Rules.

The Static and Mobile Pressure Vessels

(Unfired) Rules, 1981, (with latest
amendments) abbreviated as “SMPV (U)
Rules”. These are Rules governing the
storage, transportation; handling etc. of
compressed gas in vessels exceeding 1000
liters in volume. These rules are framed
under the Indian Explosives Act, 1884 and
administered by Chief Controller of
Explosives.

Shall.

Indicates mandatory requirement.

Competent Person

Competent person means a person

recognised by the applicable Statutory
Authority for the job in respect of which the
competency is required.
4.0 LOCATION AND presented to adjacent vessels,
SEPARATION DISTANCES equipment or installations in case
ignition occurs. Separation distances
4.1 LOCATION are not intended to provide protection
from a major incident. Risk analysis and
The location of mounded storage to be dispersion modeling are recommended
decided after careful consideration of all tools to limit the exposure risk to
influencing factors, including the adjacent facilities.
following aspects:
4.2.1 The minimum separation distances for
a) The area to be covered by mound and mounded storage shall be as follows:
the area within the separation distances,
as given in clause 4.2, shall be clear of a) Between mounded LPG storage and
any tree, stump, root, bush, combustible boundary, property line, group of
material and other objectionable matter. buildings not associated with LPG
plant shall be 15 meter.
b) Space requirement for movement of
construction/fabrication equipment and Further between edge of the mound
materials, onsite fabrication and and boundary, property line, group of
maintenance for each mounded vessel. buildings not associated with LPG
plant shall be 5 meter.
c) A detailed soil testing shall be carried
out, analysed to ascertain the suitability b) Between mounded LPG storage and
of the location and as a support any other (other than LPG
document for selection and design of pump/compressor house) facility
the foundation. associated with LPG plant (e.g.
decantation shed) shall be 15 meter.
d) The manhole and safety relief valves of
mounded vessels shall be in a well- c) Between mounded LPG storage
ventilated position. vessel and firewater pump house and
/ or Firewater tank shall be 30 meter.
e) Fire hydrants/ monitors shall
be positioned at a safe distance as All the separation distances shall be
given in item 8.0. measured from the nearest point of
the periphery of the vessel and also
f) Each mound shall have from the first exposed flange on the
accessibility to Fire Tender from at least vessel i.e. ROV.
two sides.
Further separation distance between
g) Vessel(s) shall be located such that mounded LPG storage vessel and
these do not affect or are affected by LPG pump house/compressor house
other underground structures e.g. shall be kept based on operational
foundations, pipelines, sewers, electrical needs. In case of the liquid outlet from
cables and are also not subjected to top of the mounded vessel,
loads from vehicular traffic or affected submersible pump may be installed
by other hazards like power cables, from the top of the vessel.
cathodically protected pipelines etc.
A road of minimum 3.5 m width shall
be provided around the mound for
4.2 SEPARATION DISTANCES movement of earth moving / fire
fighting equipment.
Separation distances are intended to
minimise both the potentials for small
leak ignition and exposure risk 4.2.2 The minimum inter-distance between
the edge of the vessel(s) in a mound
 shall be determined by the site for any reasons, these codes differ
conditions and the need for safe (i.e. Design code and selection of
installation, testing, maintenance and material code), the selected material
removal of vessels. However in any should confirm to equivalence of
case this distance shall not be less design code.
than 1.5 m between the vessels
having diameter of 2 m and 2 m for all a) FOR REFINERY SERVICE
other cases. (Refer attached drawing -
2) Since H2S presence cannot be
completely ruled out in the Refinery
4.2.3 The minimum inter-distance between LPG storage, high stress material
the edge of the mounds on finished shall not be used for vessels as it is
ground level shall be determined by prone to Hydrogen induced stress
the site conditions, the need for safe corrosion cracking. The material
installation, testing, maintenance and shall be selected as given below :
removal of vessels and the
requirement for the passage for i. Material shall be in line with
emergency equipment e.g. Fire design code. ASTM A516 Gr. 60
Tender, hydrant system. In any case or eqv. shall be used.
this distance shall not be less than 3.5
meter. ii. Micro-alloyed steel containing
Ni, Mo, Va shall not be
considered.
5.0 MOUNDED LPG STORAGE
FACILITIES iii. Maximum specified tensile
stress shall not be more than
5.1 STORAGE VESSEL(s) 80,000 psi.

Horizontally placed cylindrical b) FOR MARKETING INSTALLATION

vessel(s) shall be used for mounded
storage. The mechanical design of Where H2S is not present, ASTM A
storage vessel shall be based on 516 Gr.70 (IT) or SA 537 C ll (IT) or
following considerations: PD : 5500 or eqv. material shall be
used.
i) DESIGN CODE
iii) DESIGN TEMPERATURE
ASME SEC. VIII or PD - 5500 or
equivalent duly approved by CCE. A - 27 oC to + 55 oC.
single code shall be adopted for
design, fabrication, inspection and iv) DESIGN PRESSURE
testing.
14.5 Kg/cm2 g (1.42 Mpa) vapour
The specific consideration shall be pressure of LPG at top of the
given to vessel (as per IS : 4576 or IS
:14861 ) at 55 oC.
a) Internal vapour and hydraulic
pressure v) OTHER CONSIDERATIONS
b) External loadings on the vessel
c) Internal vacuum Internal Corrosion Allowance: 1.5
mm (minimum)
ii) MATERIAL
Radiography: Full
Material of construction shall
conform to design code. However, Stress Relieving:100% irrespective
of thickness.
 Earthquake pressure: as per IS: 5.2 MOUND
1893
5.2.1 Mounded vessel(s) shall be placed on
Hydrotest pressure: As per Design a firm foundation and installed so as
Code to prevent movement or floatation.
The sub-soil water, rainwater or any
The recommended design pressure other surface water should not be
and temperature shall be treated as allowed to percolate in to the mound.
MINIMUM requirement and other The foundation should be constructed
design consideration and Statutory such that in the longitudinal direction
requirements shall also be of a vessel slope of at least 1:200 is
considered. maintained to facilitate draining of the
vessel. Reference may be made to
5.1.1 The dimensions (diameter and length) attached Drawing-1 and Drawing-2.
of the vessel shall be decided based
on site conditions, soil mechanics , 5.2.2 Site conditions and soil mechanics
type of fabrication facilities available shall be deciding factors for selection
and other design considerations. of the type of foundation in a given
situation. The preferred type of
5.1.2 The external surface of the vessels foundation is a continuous sand bed,
which is covered by mound should be supporting the vessel over its full
suitably treated to protect it from length
corrosion. Methods of protection shall
include surface coatings (suitable for 5.2.3 The foundation shall have sufficient
design conditions as specified above) load bearing capacity and all the
and cathodic protection (Impressed factors affecting the foundation shall
current system). General guidelines be considered while designing the
are given in Annexure - I. NACERP- same. The factors should not be
0169, “Control of External Corrosion limited to the following:
on Underground or Submerged
Metallic Systems” and T-10D-17/T-6A- a) The load of the vessel during
63 ON “Pipe Line Rehabilitation normal operations and also during
Coatings” may also be referred. hydro test when the specific
gravity of liquid is 1 (one) instead
5.1.3 Holiday detection of the coated surface of that of LPG.
shall be carried out to ensure defect b) The earth/sand cover
free coated external surface using c) The settlement behavior of the
suitable Spark Holiday Detector. foundation which include

5.1.4 The cathodically protected system i) Overall settlement

shall be isolated from the unprotected ii) Differential settlement which
structures /surfaces by installing causes bending of the vessel
monolithic joints i.e. one each on iii) Differential settlement which
liquid and vapour lines. A suitable causes sloping of vessel
isolation shall also be provided on
utility pipelines such as air line to 5.2.4a) The sand bed beneath the vessel
ROV, metallic structures, instrument shall be of adequate elevation not less
lines etc. than 0.76 meter to facilitate drainage
from liquid outlet pipe by gravity. In
5.1.5 Reference points on inner surface of this case, bottom connection shall be
the vessel shall be marked for NDT, permitted on mounded vessel(s) with
for subsequent inspections. an access to connections by providing
an opening or tunnel with 1.2 m
 minimum diameter and a 0.9 m continuous impermeable cover shall
minimum clear area. Bottom not be installed, to prevent the
connections shall be considered as possibility of gas accumulation inside
part of the vessel where these extend the mound.
beyond the mound and shall be Proper drainage and slope on top of
designed for the forces that can act on the mound shall also be provided.
the connection.
5.2.9 Longitudinal axis of vessels (any
Proper provision shall be made for number) in a mound shall be parallel
encountering the consequences of the to each other with ends in line.
settlement of the vessel. The
surrounding of the bottom connection Where more than one row is installed
should be filled with such material that the adjacent ends of the vessel in
can absorb such settlement. each row shall be separated by not
less than 3 meter.
Reference may be made to attached
Drawing-2 and Drawing -3. 5.2.10 The valves and appurtenances of
mounded vessel(s) shall be
b) Where submersible type of pumps is accessible for operation or repair,
provided for individual vessel, without disturbing the mound.
conditions stated at “a)” above shall
not apply. In such cases drainage of 5.2.11 Provision shall be made to monitor the
water shall be made by using dip pipe settlement of the mound/ vessel by
with top connected drain valves. The providing permanent reference points.
first valve on this pipeline shall be A minimum of three reference points
provided as close to vessel as shall be provided to ascertain uniform/
possible and shall be kept close differential settlement and also
condition in normal operating identify possible vessel bending (One
conditions. each near the vessel ends and one in
the middle.)
5.2.5 The mound shall protect the vessel
from the effects of thermal radiation Maximum permissible differential
and shall be sufficiently robust to settlement shall be determined at the
remain in place in the event of jet project design stage. Procedures shall
flame impingement. be developed to regularly monitor the
settlement throughout the lifetime of
5.2.6 Mound shall be of earth, sand or other the vessel and records maintained
non-combustible, non-corrosive thereof.
material such as Vermiculate or
Perlite and shall provide at least 700 5.2.12 Provision shall be made for inserting
mm minimum thickness of cover for portable CuSO4 reference electrode
the vessel. on top of the mound for measurement
of PSP at 12 - O Clock position of the
Reference may be made to attached vessel. This shall be protected to
Drawing-4 prevent water ingress in the mound.

5.2.7 The mound surface shall be protected Reference may be made to attached
against erosion by rain or wind by Drawing-2.
providing a suitable protective cover of
prefabricated stone, open concrete
tiles, etc..
6.0 FITTINGS AND INSTRUMENTS
5.2.8 Water ingress into the mound shall be ON A VESSEL
minimised by providing impervious
layer of suitable material. However, a
 All the fittings / instruments shall be intermediate valve on downstream
suitable for use at not less than the side at an elevation of 3-meter
design pressure of the vessel and for (minimum) from the top of the mound
the temperatures appropriate to the or exposed nozzle whichever is
worst operating conditions. Various higher for effective dispersion of
fittings and instruments to be provided hydrocarbons. A weephole with a
on the vessel are as under : nipple at low point shall be provided
on the vent pipe in order to drain the
6.1 The fire safe Remote Operated Valve rainwater. Weep hole nipples shall
(s) (ROV) shall be provided on first be so oriented that in case of safety
flange on liquid line (s) from the valve lifting and consequent fire, the
vessel either from bottom or top as flame resulting from LPG coming out
per the design considerations. There from weephole does not impinge on
shall not be any other flanges, or any the vessel or structure. A loose
other tapping up-to the ROV, fitting rain cap with a chain (non-
structures, . sparking) fitted to vent pipe shall be
provided on top of SRV.
In case of provision of liquid outlet
from the top of the vessel, the line 6.4 The flange joints of valves shall either
shall extend upto bottom. have spiral wound metallic gaskets or
ring joints. Plain asbestos sheet /
In case of liquid line from the bottom reinforced gaskets shall not be used.
of the vessel, the minimum distance of
3 m from the vessel to ROV shall be Flange connections shall be a
maintained. The nozzle pipe shall minimum of ANSI-300 lb flange class.
have a slope of minimum 1.5o.
Reference may be made to attached 6.5 Each storage vessel shall have
Drawing-3. minimum two different types of level
indicators and one independent high
The top of the vessel shall be level switch. High level alarm shall be
provided with nozzles for vapour outlet set at not more than 85% level of the
and re-circulation, which shall also be volumetric capacity of the vessel.
provided with fire-safe ROVs.
Audiovisual indication shall be
6.2 Minimum two nos. of manhole shall be provided at local panel & control room.
provided on top of the vessel.
6.6 Each vessel shall also be provided with
6.3 Each vessel shall have at-least two one pressure and temperature
Safety Relief Valves (SRV). The full measuring instrument. The pressure
flow capacity of each SRV on gauge shall be provided with two
mounded vessel(s) shall be minimum isolation valves and an excess flow
30 % of the capacity required for an check valve.
equivalent size of above ground
vessel. In case, temperature gauge provided
on the vessel is in thermo well, it shall
The discharge of SRVs shall be be welded to vessel.
connected to flare system wherever
available. SRVs shall have lock open 6.7 In areas where heavy snowfall can be
(or car seal open) type isolation expected, piping, regulators, meters,
valves on both sides of SRV. and other equipment installed in the
piping system Ishall be protected from
In case of non-availability of flare the forces anticipated as a result of
system, the discharge from safety accumulated snow.
valve shall be vented vertically
upwards to atmosphere without any
7.0 HAZARDOUS AREA In addition, devices for initiating all the
CLASSIFICATION above actions shall be provided on
remote operating panel and also in
The hazardous area shall be classified field at safe location to enable manual
as per IS : 5572 and OISD-STD-113. actuation. Suitable arrangement for
The electrical fittings/ equipment in the routine testing of security system shall
respective classified area/ zone shall be provided.
be of a type suitable for the particular
area/zone as per classification in line 8.2 GAS DETECTION SYSTEM
with IS : 5571.
Suitable gas detectors shall be placed
at critical locations in the LPG storage
8.0 FIRE DETECTION / area such as near the ROVs, in
PROTECTION SYSTEM inspection tunnel, inside the nozzle
box enclosure (if provided) or dome
The fire detection / protection system for connection, near water draining/
the mounded storage area shall be as sampling points.
follows;
Audio-visual alarms showing the
8.1 AUTO FIRE DETECTION / location of gas leakage shall be
PROTECTION SYSTEM provided on the control panel. First
level alarm shall be set at 20% of
Automatic fire detection and /or Lower Explosive Limit (LEL) and
protection (Fixed) system based on heat second level alarm at 60 % of LEL.
detection through thermal fuses/ quartz
bulbs/ EP detectors shall be provided. 8.3 WATER REQUIREMENT / STORAGE
Sensors shall be installed at all critical
places as below: The mound of vessel (s) provides
protection against direct flame
a) Minimum One detector shall be impingement and minimises heat
provided on each exposed portion of absorption from nearby fires.
the vessel. However, if the nozzles Therefore, for water requirement /
are covered in a dome, each group storage in mounded storage area, the
shall have at least two detectors. clauses of OISD - STD –144 w.r.t.
medium velocity water sprinklers shall
b) At least one detector shall be provided not be applicable
near ROV on all liquid line (s). 8.4 The fire proofing ( 2 Hours rating) of all
exposed portion of the vessel shall be
The actuation of pressure switch on any done including piping upto the first
one of above said detector on or around ROV,appurtenances etc. Alternatively,
the mound shall initiate the following: auto actuated fixed water spray
system shall be provided and this
- an audiovisual alarm at the local/ system should be actuated through
main control panel and fire water heat detection device installed as per
station, indicating the fire. above clause 8.1.
- All ROVs on the affected vessel Reference may be made to attached
shall close. Drawing-4, and Drawing-5.

- LPG pumps and compressors in 8.5 Hydrant (s) / monitor (s) coverage shall
LPG storage area shall trip. be provided for adequate coverage of
unprotected portions exposed to
- Sprinklers. If provided, shall thermal radiation including the top of
operate. the mound and product pipelines.
8.6 Hydrant (s)/monitor(s) shall be located immediately (within the first
at a safe place and shall not be second or two) after
installed within 15 meters from the simultaneously interrupting the
exposed portion facilities/equipment to current output from all cathodic
be protected. protection sources affecting that
portion of the vessel.
8.7 Measures to prevent the freezing of
cooling water supplies and frost iii) The PSP readings shall also be
damage to supply lines, etc. shall be recorded on weekly basis with
provided in the areas where heavy respect to permanent Zinc
snowfall can be expected. reference cell.

iv) The polarisation cell shall be

9.0 OPERATION, MAINTENANCE checked regularly for replenishing
AND INSPECTION the liquid levels(KOH).

The following provisions specific to v) The protective current shall be

mounded storage facility shall be monitored quarterly.
followed and records to be
maintained: b) Insulating Joint/Coupling Inspection

9.1 Safety Relief valves shall be tested Insulating joints and couplings shall be
and calibrated every year by a inspected once in a year.
competent person.
9.3 The settlement of the vessel shall be
9.2 Cathodic protection system, shall be monitored at least on half yearly basis.
maintained, tested as below :
9.4 Vessel (s) shall be subjected to hydro
a) Pipe to Soil Potential (PSP) Readings test once every 10 years or at every
welding to the vessel (repairs or new
i) PSP readings at feeding points connections) whichever is earlier, by a
shall be monitored fortnightly. competent person.

ii) The PSP reading at the test lead 9.5 Vessel (s) shall be tested every 5 years
points for entire vessel shall be internally using visual and other
taken once in a quarter. The PSP techniques for the following:
survey results shall be plotted
graphically to identify and locate a) All the weld joints of the vessel shall
cathodic holidays. The minimum be examined through Non-
PSP shall be more negative than Destructive Testing (NDT)
- 0.85 volts with respect to techniques e.g., radiography, Wet
copper/copper sulphate half-cell. Magnetic Particle Test (WPT), Dye
In areas where anaerobic bacteria Penetration Test (DPT), ultrasonic
are active minimum PSP shall be flaw detection to ensure the integrity
more negative than - 0.95 volts of the joints.
instead of - 0.85 volts. Over
protection of coated vessel shall b) The wall thickness of the vessel
be avoided by ensuring that shall be measured ultrasonically.
polarisation potential is below
- 1.2 volts with respect to copper/ For (a) and (b) above other established
copper sulphate half cells. NDT techniques may be used for
Polarisation potential shall be example acoustic emission testing.
measured at a given location on a
coated vessel by measuring PSP 9.6 In case of any indication of defect or
doubts about any defect, the
 mound cover of the vessel shall Rehabilitation Coatings”, Nace
be removed to expose the outer International, U.S.
surface for necessary examination
from outside.
(f) Other Standards /specifications as
9.7 If internal access to mounded vessel is referred in the different clauses of this
not possible, the external surface of standard.
the vessel shall be exposed to enable
examination.
Note : The attached drawing 1 & 2
9.8 Any repairs or modifications shall be are typical and are being modified.
carried out only after taking approval
from applicable authority.

9.9 A manual for operation and

maintenance procedure with
necessary details for both normal and
emergency operation shall be
developed.

10.0 REFERENCES

(b) NFPA 58 – Liquefied Petroleum Gas

Code, U.S.

(c) Technical Paper on “Developments in

the storage of dangerous gases and
liquids in large capacity tanks” by Dr.
F.Mang, University of Karlsruhe.

(d) OISD-STD-116, OISD-STD-118,

OISD-STD-144, OISD-GDN-169 &
OISD-STD-210

(e) NACERP-0169, “Control of External

Corrosion on Underground or
Submerged Metallic Systems” and T-
10D-17/T-6A-63 on “Pipe Line
 ANNEXURE - I

GENERAL GUIDELINES FOR CATHODIC PROTECTION SYSTEM

1.0 General
The cathodic protection system shall be designed by and installed under the supervision of a
specialised cathodic protection personnel.

The design of the cathodic protection system shall be an integral part of the total vessel design.
Electrical isolation of piping and a suitable coating system shall be provided for in the vessel
design.

2.0 Protection Criteria

In this specification only the structure to soil potential is used as a criterion for effective cathodic
protection.

For the vessels to be considered fully cathodically protected, the “OFF” potential on all parts of
the vessels shall be equal to or more negative than -850 mV vs Cu/CuSO4( +250 mV vs Zinc)
reference.

If anaerobic conditions and activity of sulphate - reducing bacteria are present or likely, the “OFF”
potential shall be equal or more negative than –950 mV vs Cu/CuSO4 (+150 mV vs Zinc )
reference.

To avoid detrimental effects on the applied coating or on the metal due to overprotection, “OFF”
potentials shall not be more negative than –1150 mV vs Cu/CuSO4 ( -100 mV vs Zinc) reference.

3.0 Design
The following data shall be considered for cathodic protection design. :

- number of vessels with dimensions and locations

- design life of the installation
- external coating specifications
- plot plans, location of vessels, piping etc.
- piping diagrams and electrical diagrams showing electrical is9olation and earthing
systems
- relevant construction drawings of the vessels and foundation
- soil and groundwater conditions including resistivities
- adjacent buried metal and reinforced concrete structures
- existing and planned cathodic protection systems
- possible sources of interference
- availability of electrical supply
- hazardous areas classification
- further requirements by the company on potential control, monitoring facilities.
4.0 Electrical Separation
Each vessel shall be electrically isolated from other vessels, pipelines, plant, buried metal
structures and electrical and instrument earthing systems.

Monolithic isolating joints shall be installed above ground in all piping attached to each
individual vessel. These joints shall be suitable for the expected temperature range as given in the
design data.

The resistance across isolating joints shall be measured immediately before welding into the
pipeline. The minimum resistance shall be 1 mega ohm (106 ohm).

Isolating joints shall be painted in a contrast colour for easy identification.

Safety and instrument earthing installed on the vessels shall be provided with polarization cells to
avoid loss of cathodic protection current while maintaining a low resistance to earth.

If more than one vessel is installed, polarization cells shall be installed in the earthing of each
individual vessel to ensure electrical insulation between the vessels.

The polarization cells shall be suitably rated for the expected voltages and currents.

5.0 Transformer / Rectifiers

Transformer/rectifiers shall be of a special design for cathodic protection service.

The output voltage shall be adjustable from, zero to the rated maximum voltage. A stepless
(continuous) adjustment shall be used, without adjustment by tapping switches.

Electronic voltage and/or current control is recommended in combination with automatic potential
control.

The rectifier shall be constructed using high current density selenium cells or silicon diodes so
arranged to provide full wave rectification. The AC-component of the secondary voltage under
the most unfavorable load conditions shall not exceed 10 % of the DC-output.

The transformer/rectifier shall be provided with a moulded case circuit breaker on its incoming
circuit and suitably sized fuses shall be installed in the incoming AC and negative DC output
circuit.

The transformer/rectifier shall be provided with meters to read the ;output voltage and current.
The measuring accuracy shall be 2 % of full scale or finer.

The polarity of the DC terminals and AC supply cables shall be clearly marked. AC and DC
cables shall be physically separated by an insulating panel.

Transformer /rectifiers should be installed in a non-hazardous area.

When installed outdoors, the enclosure shall be weather-proofed.

6.0 Automatic Potential Control

The cathodic protection system shall be provided with automatic potential control. A switch shall
be provided to switch the system between automatic and manual operation.

In automatic operation mode, the control circuit shall be capable of controlling the current output
such that the structure to soil potential at the connected reference cell is maintained within 10 mV
of the set value at the prevailing current demands during any period in the design life.

The potential measuring circuit shall have an input resistance of more than 100 mega-ohms and
be capable of working with both Cu/CuSO4 and Zinc reference cells.

The control system shall be provided with adjustable voltage and current limiting circuits and /or
alarms to avoid overprotection of the vessel in case of failure of a reference cell.

A panel mounted meter to read the structure-to-soil potential at the selected control reference cell
shall be provided.

7.0 Cables and Distribution Boxes

The connections of electrical cables to the vessel shall be designed to ensure adequate mechanical
strength and electrical continuity and to prevent damage to the vessels.

The cable connections may be made by, welding, pin brazing or by mechanical means. Thermit
welding or brazing to the vessel wall shall not be used.

Mechanical connections shall be made above ground only using cable lugs, nuts and serrated
washers.

All below-ground electrical connections to the vessel shall be fully encapsulated to comply with
the original vessel coating standards and shall be holiday tested before backfilling.

All cables shall be sized such that no excessive voltage drops occur which reduce the capacity of
the system.

All cables shall be insulated and sheathed to withstand the prevailing soil conditions. Drain cables
and grounddbed feeder cables shall be armoured. All cables shall be buried in soft sand at a
depth of at least 0.5 m, provided with cable protection tiles or warning tape as considered suitable
for the area.

All cables shall be identified by cable tags where they come above ground.

8.0 Design Documents

These design documents shall contain the following :

- results of site surveys carried out for the design.

- Calculation of current requirements and resistance and current capacity of groundbeds.
- A schematic diagram of the proposed cathodic protection system.
- Diagram of the proposed monitoring facilities.
- Material schedules.
- Installation procedures with all relevant construction drawings and details.
 - Commissioning requirements and procedures.

9.0 Commissioning
The commissioning of the cathodic protection system shall be carried out by competent person
under supervision.

The commissioning shall comprise of following :

- visual examination of all system components, checking of all cable connections and
polarity.
- Checking of all permanent reference cells with respect to a portable reference cell before
energizing the system.
- Measurements of groundbed resistance to remote earth.
- Measurements of natural potentials at each permanent monitoring location.
- Energizing the system and current adjustment to obtain approx. protection potentials.
- Checking of the electrical isolation of each vessel.
- “OFF” potential measurements after at least 48 hours of polarization.
- Any other monitoring and readjustments required to meet the protection criteria.

A commissioning report shall be written containing the following :

- a brief description of the system.

- All information on the deep-well ground beds (depth, resistivity/depth profiles, active
depth and length, anode arrangements).
- Results of all commissioning test procedures.

10.0 Operation and Maintenance

Operation and maintenance manual for the cathodic protection system shall cover the following :

- description of the system and system components, controls and connections

- as – built drawings.
- Manufacturer documentation
- A schedule of all monitoring facilities.
- Potential criteria for the system.
- Monitoring schedules and requirements for monitoring equipment.
- Monitoring procedures for regular (ON/OFF) measurements.
- Test procedures for electrical isolation integrity.
- Methods for readjustment of the system.
- Guidelines for the safe operation of the system.

11.0 Additional Design Considerations

Mounded storage designs other than those using sandbed foundations require additional buried
metal or reinforced concrete structures to support the vessel. Those buried structures are sources
for shielding and interaction with the vessel’s cathodic protection system. Because of this, such
designs are not optimal from a corrosion protection point of view, however, conditions may exist
which prohibit the use of sand bed foundations.
When those foundation designs are used, the following points shall be considered in the cathodic
protection design.

- foundation piles, rafts and supports shall be electrically isolated from the vessel using
suitable isolating sheets where metallic contact might occur.
- In locations where the vessel’s surface is covered by insulating materials, e.g. resilient
material, or where settlement of soil may prevent intimate soil contact, effective cathodic
protection may be inhibited. Where such a situation is expected, additional measures
shall be proposed to ensure adequate corrosion protection. Such measures may consist
of e.g. additional coating or corrosion allowance and shall always be proposed together
with inspection methods to prove the effectiveness of these measures.
- Shielding effects by foundations and access tunnels may require special groundbed
designs, e.g. anodes inside the mound. Such designs shall be accompanied by full
justification and design calculations.
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 Drawing 5

Note 1

11